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Why Choose aChassis Dynamometer?
We Make Your Testing Easy
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Dan JensRegional Accounts [email protected]
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AGENDA
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What is a Chassis Dynamometer
Why an Eddy Current Dyno?
Why do I need a Chassis Dynamometer
What is aChassis Dynamometer?A chassis dynamometer measures the power delivered to the surface of the driver roller by the drive wheels. Vehicles are positioned on the rollers, which the vehicle then turns to measure the output.
Data acquisition and control packages for your testing needs
Main Components of a Chassis Dynamometer
Precision Machined Rollers
Multi-Axle Variants
Varying Absorption
Technologies
Eddy CurrentChassis Dynamometers
20” diameter rolls have 30,000 lbof vehicle weight capacity per drive axle and come with a lifetime warranty
Structural steel frames, with lifetime warranty, provide durable dependable product performance
Air-cooled eddy current load absorbers provide a heavy-duty, cost effective, and water-free solution.
Large 40” diameter, water brake chassis dynamometers allow greater
operation speeds and peak HP capacities
Utilize direct coupled water brake absorbers, and weight capacities to 30,000 lbs per
drive axle
Allows for drastically increased testing duration
and longer tire life
Large RollChassis Dynamometers
How do you knowwhich system is right for you?
Why an Eddy CurrentChassis Dynamometer?
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Why an Eddy Current Dyno?
Typical Water Brake Chassis Dyno:
Water supplied to water brakes provides resistive force, or ‘load’
Water is heated rapidly and needs to be continuously cooled or drained to sewer
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Non-Green Water Brake Cooling Solution:
Utilizes municipal water and dumps hot water to sewer
Water usage: Approx. 400 gal per test
For 80 tests per month (20 per week, or 4 per day) = 390,000 gal per year
Annual Water/Sewer Cost: $5,900 (avg. U.S. rate = approx. $15/1,000 gal.)
Why an Eddy Current Dyno?
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Cooling System Pumps and Control Panels.
Why an Eddy Current Dyno?
Roof-top 100 HP cooling tower 5,000 gal. outdoor storage tank(INDOOR required if freezing climate)
Water Brake Cooling Solution:Utilize an accompanying Cooling Water System
Cooling System Expense:Approx. $50,000 Investment
System Equipment Price: approx. $30,000Installation Price: approx. $20,000 min. Pump Electrical Consumption: Varies
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Water Brakes Present Operational Headaches and ExpensesA Water Brake dyno pit often becomes filled with water, oil, and debrisGearboxes are often needed to increase water brake RPM and provide adequate load at slower speeds
Gearboxes require lubrication to avoid catastrophic failure Gearboxes and water brake components are generally replaced every 7-10 years
Dyno pit is susceptible to clogged drains and flooding, which ruins vented gearboxWater brakes clog with mineral deposits over time and no longer create load
Cost of replacement is approx. $28,000-$35,000 for 2 water brakes and 2 gearboxes
Why an Eddy Current Dyno?
Water Brake
Gearbox
*normal configuration is 2 of each
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Eddy Current Chassis Dynos (Green Solution as-is):Air-cooled, waterless system
No water in pit other than dripping from vehicle
Eddy current brakes utilize electricity and magnetic fields to create load
No gearboxes needed – Eddy’s create adequate load at all normal operating vehicle speeds
Only greasing is for bearings and carried out from easily accessible central manifold
Extremely fast response time
Minimal Electrical use (no water consumption):
Approximate use: 1.4 kW-hrs per test
For 80 tests per month, 1,343 kW-hrs per year
Annual Electricity Cost: $161
Eddy Current ElectricBrakes
Why an Eddy Current Dyno?
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Total Cost of Ownership Comparison Power Test
Eddy Current Competitor Water Brake
(Water Brake vs. Eddy Current Chassis Dyno)
Lubricate all shaft bearings monthly (or 40 hours, whichever comes first): $72 $2,160Adjust water brake packing seals approx. every 2 months: $0 $540
Calibrate every 6 months: $12 $60Clear clogged Dyno Pit drain of debris bi-annually on average: $0 $250
Replacement of 2 Water Brakes & 2 gearboxes & water pumps every 7-10 yrs on avg: $0 $3,706Annual parts costs outside major equipment replacements: $461 uncertain
Annual Electricity charges for Eddy Currents: $161 $0Water & Sewage Charges for Water Brakes withOUT cooling system: $0 $5,743
Water treatment chemicals and service (with coolling system in place): $0 $1,000
Power Test CompetitorAnnual
Difference: Year 2 Year 3 Year 4 Year 5 year 6 Year 7 Year 8 year 9 Year 10Annual "Total Operating Cost" using water & sewer: $706 $12,459 $11,752 $23,505 $35,257 $47,009 $58,762 $70,514 $82,266 $94,019 $105,771 $117,523Annual "Total Operating Cost" with cooling system: $706 $7,716 $7,010 $14,019 $21,029 $28,038 $35,048 $42,058 $49,067 $56,077 $63,086 $70,096
Why an Eddy Current Dyno?
Total Cost of Ownership Compare
Power Test CONFIDENTIAL
Prepared by Power Test, Inc.
January 1, 2017
"Total Cost of Ownership"
Eddy Current Cost Savings vs. Water Brake Chassis Dyno options
Power Test is a proven BEST VALUE due to:1. Reputation for high-quality service and responsiveness to our customers, including no-charge phone & email support, along with value-added services like our proprietary “Payback Calculation” methodology2. Reliability of our product. Robust design quality that is meant to last with high-quality materials & components, producing extremely long-life, as evidenced by our lifetime warranty on frame and rolls-sets3. Low operating and maintenance costs, consuming only minor amounts of electricity annually, and requiring only simple bearing lubrication from a central manifold for regular maintenance4. Fair equipment prices, considering quality of design, materials and construction, along with benefits mentioned above and below
Initial Purchase
Chassis Dyno ModelCF22EC-4BCF22EC-4LB or -4RBCF22EC-4LB or -4RB w/ Ramp & Gap Kit
3-year Extended Warranty (beyond 12 mo.)
Years 2 & 3 coverage savings per unit @ 3% equip price per year:6.0%$7,029$7,666$7,937
(PNet computer, Handheld & printer price removed from calc)
Cooling Tower avoidance (cooling water required for Water Brake designs)
100 Hp tower w/ 5,000 gal storage, pumps controllers:$30,000
Installation (min.):$20,000
Total Cost Avoidance (min.):$50,000
Ongoing Annual Expense/Savings
Eddy Current vs. water brake chassis dyno
gal/testTests/monthGal/yr$/1,000 galTotal Annual Expense
(Water Brake) Water & Sewer if no cooling system:41080393,600$15$5,904
kW/testTests/monthkW-hrs/yr$/kW-hrTotal Annual Expense
(Eddy Current) Electrical Charge for Eddy Unity excitation:1.4801344$0.12$161
Incremental Utility Expense of Water/Sewer vs. Eddy Electricity:$5,743
Replacement of Gearboxes and Water Brakes
2 water brakes and 2 gearboxes and system water pumpsLowHighAvg
replacement Cost:$28,000$35,000$31,500
replacement frequency (yrs):7108.5
Average Annual Replacement Expense:$3,706
Labor Rate/Cost/Profit assumptions:
Assume labor billing rate ($/hr) =$ 100
Assume fully-burdened labor cost ($/hr) =$ 40
Lost opportunity profit due to required maintenance work ($/hr) =$ 60
Total Cost of Ownership ComparisonPower Test Eddy CurrentCompetitor Water Brake
(Water Brake vs. Eddy Current Chassis Dyno)Assumption: Any technician time spent on dyno maintence is treated as lost profit opportunity since not billing labor rate to customer
Lubricate all shaft bearings monthly (or 40 hours, whichever comes first):$72$2,160WB: 3 man-hours to remove multiple cover plates, and grease individual bearings. (PTI: 3 min to lift single, hinged cover and apply grease via single, central manifold. no tools besides grease gun required)
Adjust water brake packing seals approx. every 2 months:$0$540WB: 1.5 man-hrs each time to take off individual cover plates, mount truck, spin rolls, apply max water, tighten packing. (PTI has no packing seals to adjust)
Calibrate every 6 months:$12$60WB: 0.5 man-hour to remove cover plates, crawl into pit, mount cal arm and weitghts & cal. (PTI: approx. 5 min: no covers must be removed; no tools required)
Clear clogged Dyno Pit drain of debris bi-annually on average:$0$250WB: Chasis Dyno pit drains are subject to clogging. Assume once/2 years, and approx $500 charge go clear. (PTI: no drainage of any significance through floor drain)
Replacement of 2 Water Brakes & 2 gearboxes & water pumps every 7-10 yrs on avg:$0$3,706WB: Common need to replace 2 water brakes and 2 gearboxes every 7-10 yrs at approx. $28,000-$35,000 expense. (PTI: no common major component replacements.)
Annual parts costs outside major equipment replacements:$461uncertainWB: uncertain of annual smaller costs, but likely same or greater than Eddy Current. (PTI value determined from actual records from 33 customers spanning 8 years)
Annual Electricity charges for Eddy Currents:$161$0WB: no Eddy Current electricity usage. (PTI: Based on 80 tests/month, eddy current electric draw 1.4kW/test, electricity cost $0.12/kw-hr)
Water & Sewage Charges for Water Brakes withOUT cooling system:$0$5,743WB: water & Sewer fees apply for cases in which no cooling system exists. Based on 80 tests/month, approx. 410 gal/test, $1,000/gal. (PTI: No cooling water needed)
Water treatment chemicals and service (with coolling system in place):$0$1,000WB: normally hire a 3rd-party firm (to avoid liability or mistakes) to maintain quarterly at approx. $1,000/yr. (PTI: No cooling system needed)
Power TestCompetitorAnnual Difference:Year 2Year 3Year 4Year 5year 6Year 7Year 8year 9Year 10
Annual "Total Operating Cost" using water & sewer:$706$12,459$11,752$23,505$35,257$47,009$58,762$70,514$82,266$94,019$105,771$117,523
Annual "Total Operating Cost" with cooling system:$706$7,716$7,010$14,019$21,029$28,038$35,048$42,058$49,067$56,077$63,086$70,096
Additional Cost Savings from elimination of On-road test drives
No need for all technicians to maintain CDL's:Dependent on location and best determined by Service Manager
Reduce accident liability risk and insurance premiums:Dependent on location and best determined by Service Manager
Eliminate unproductive technician time (traffic, hooking up trailer, coffee breaks, etc.):Dependent on location and best determined by Service Manager,
Additional Value-Add's for Power Test
Pre-loaded PowerNet Test Patterns: PowerNet comes loaded with 5 standard test patterns (J1708 @ 1,800 rpm; J1708 @ 2,100 rpm; J1939 @ 1,800 rpm; J1939 @ 2,100 rpm; Manual Test) 'covering 95% of testing needs
No-Charge ongoing phone and email technical support: Ranges from zero hours/year to 10 hours/year, depending on chassis dyno user & location (Up to $1,250 in no-charge benefit per year).
Dyno Training - Operations and Maintenance: 1. Startup, Commissioning and Training for all new unit purchases:
-Operations, Safety and Maintenance Training offered to 3-5 DBU-designated dyno operator technicians at the particular DBU
-Onsite, 3-day commissioning and training, billed at $995/day, plus 2 days travel at $595/day and agreed upon fixed travel expenses
2. REFRESHER training sessions also be available for DBU technician training as reqeusted by DBU or regions
-2 days on-site at Cummins DBU and billed at $995/day plus 2 days travel at $595/day plus agreed upon fixed travel expense applies
-Content to include: Maintenance, Safety & Operation, including test pattern creation and use, along with ECM interface
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LOW Maintenance Costs & Maximum Up-Time
SIMPLE installation
NO cooling system needed
Green Technology
HIGH Reliability
No flooded, smelly pits
No water chemistry
FEW headaches
Why an Eddy Current Dyno?
Why Do I Need aChassis Dynamometer?
www.powertestdyno.com +1 262 252 4301
Eliminates liability and lost time from road testing
Lower liability insurance rates
No traffic jams to get stuck in and ZERO risk of traffic accidents
No drive time to get to areas where you can only partially test engine cooling and performance
Immediate ability to re-create performance complaint issue
Ability to fully replicate any MPH, RPM, or output load level while recreating a reported issue
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Eliminates multiple staff deployed for road testing
Allows technicians more time to work billable hours in the shop
No second technician needed to read the OEM PC software
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Proper and professional verification of repair
Proves that performed services have resolved the customer’s reported issues
Increased customer satisfaction with your service organization
Instantaneous credibility and confidence in your repair
Significant value add in providing professional reports
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Reduction or elimination of come-backs
Reduced risk of warranty coverage
Increase of service volume from referrals
Simulates loaded conditions under inaccessible terrain
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Incremental Shop Income
Additional performance issues can only be identified on the dyno
These issues may not be found on a normal test drive
Former drive time is now replaced with additional billable repair time.
Increase in parts sales derived from increased repair time
The market allows you to charge for dynamometer testing services
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Additional Business Benefits
Proves to your customers your dedication and ability to efficiently identify and resolve their equipment issues
Ability to test used trucks prior to accepting them in a trade
Dynamometer testing services for outside organizations, including your competition
Provides a direct benefit to used truck business.
Properly assess trade in values
Tout it as a value add during the sale
How do I Know it Pays back?
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Cost Calculator
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Dan JensRegional Accounts Manager
Contact Power Test to work through your own payback
calculator
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+1 262 253 4301
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